Encased foldable wall bed

ABSTRACT

A foldable wall bed including a housing frame, a bed frame, and a casing. The housing frame is configured to be secured to a structure and defines a storage space. The bed frame is configured to support a mattress. The bed frame presents a proximal end that is pivotally secured to the housing frame. The bed frame is pivotable about an axis between a storage position and an in-use position. The casing substantially encloses the housing frame and the bed frame to define an outermost circumambient surface of the bed when the bed is arranged in the storage position or the in-use position.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority from U.S. Provisional Application No. 62/157,728, filed May 6, 2015, the entire disclosure of which is hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to furniture. More particularly, the present invention relates to foldable wall beds or cabinet beds.

2. Discussion of the Prior Art

Facilities that accommodate overnight stays generally provide some form of furniture to guests or visitors. The choice of furnishments is largely dependent on available space, sanitation, and safety. This is especially true for hospitals and other healthcare facilities.

Because of spatial restrictions, most hospitals cannot provide separate beds for visitors and caregivers. Often, visitors and caregivers must sleep in chairs or even on the floor if they wish to stay with the patient overnight or for prolonged periods. Some hospitals provide more accommodating furnishings, such as pull-out couches or folding beds. However, known versions of such furnishings are difficult to clean, which can be detrimental in healthcare facilities where sanitation is paramount. Furthermore, many of these devices have exposed or readily accessible moving parts that can injure the user.

SUMMARY

The following brief summary is provided to indicate the nature of the subject matter disclosed herein. While certain aspects of the present invention are described below, the summary is not intended to limit the scope of the present invention.

Embodiments of the present invention provide a foldable wall bed that does not suffer from the problems and limitations of the prior art.

One aspect of the present invention concerns a foldable wall bed that includes a housing frame, a bed frame, and a casing. The housing frame is configured to be secured to a structure. The housing frame defines a storage space. The bed frame is configured to support a mattress. The bed frame presents a proximal end that is pivotally secured to the housing frame. The bed frame is pivotable about an axis between a storage position and an in-use position. The casing substantially encloses the housing frame and the bed frame to define an outermost circumambient surface of the bed when the bed is arranged in the storage position and the in-use position.

Another aspect of the present invention concerns a foldable wall bed that includes a housing frame, a bed frame, and an auto-synchronized leg deployment assembly. The housing frame is configured to be secured to a structure. The housing frame defines a storage space. The bed frame configured to support a mattress. The bed frame presents a proximal end that is pivotally secured to the housing frame. The bed frame is pivotable about an axis between a storage position and an in-use position. The leg deployment assembly is configured to deploy a support leg when the bed is moved to the in-use position and retract the leg when the bed is moved to the storage position.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Preferred embodiments of the invention are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is a front isometric view of a wall bed constructed in accordance with the principles of a preferred embodiment of the present invention, depicting the bed operably arranged in the storage position;

FIG. 2 is an isometric view of the wall bed shown in FIG. 1, depicting the bed operably arranged in the storage position;

FIG. 3 is an isometric view of the wall bed of FIG. 1, depicting a user P moving the bed from the storage position;

FIG. 4 is an isometric view of the wall bed of FIG. 1, depicting the bed operably arranged in the in-use position;

FIG. 5 is a fragmentary isometric view of the wall bed of FIG. 1, particularly showing the preferred arrangement of the left side of the bed housing;

FIG. 6 is a front isometric view of the wall bed of FIG. 1, depicting the bed arranged in the in-use position with the casing removed and showing the preferred arrangement of the frame sections;

FIG. 7 is an enlarged, fragmentary, vertical cross-section view of a portion of the bed of FIG. 1, particularly depicting the preferred relationship between the leg deployment assembly and the lower right portion of the bed;

FIG. 8 is a front isometric view of the wall bed of FIG. 1, depicting the side panels and the horizontal frame member exploded away from the vertical housing frame sections;

FIG. 9 is a rear isometric view of the wall bed of FIG. 1, depicting the top, back, and bottom panels exploded away from the vertical housing frame;

FIG. 10 a front isometric view of the wall bed of FIG. 1, depicting components of the bed exploded away from the bed frame;

FIG. 11 a rear isometric view of the wall bed of FIG. 1, depicting components of the bed exploded away from the bed frame;

FIG. 12 is a side view of the wall bed of FIG. 1, with a portion of the left side panels and a portion of the left vertical frame section removed to show the positioning of the lift assist assembly and the headboard assembly with the wall bed in the storage position;

FIG. 13 is a vertical cross-section view of the wall bed of FIG. 1, particularly showing the arrangement of the auto-synchronized leg deployment assembly in the storage position;

FIG. 14 is a vertical cross-section view of the wall bed of FIG. 1, particularly showing the bed positioned between the storage and in-use positions;

FIG. 15 is a vertical cross-section view of the wall bed of FIG. 1, particularly showing the bed positioned between the storage and in-use positions;

FIG. 16 is a fragmentary perspective view of the wall bed of FIG. 1, showing the relationship of the proximal and distal end portions of the leg deployment assembly with the bed in the in-use position;

FIG. 17 is a fragmentary vertical cross-section view of the wall bed of FIG. 1, particularly showing the relationship of the proximal and distal end pulleys with the bed in the in-use position;

FIG. 18 is a front isometric view of a wall bed constructed in accordance with the principles of an alternative embodiment of the present invention, depicting the bed operably arranged in the storage position;

FIG. 19 is a front isometric view of the wall bed of FIG. 18, showing the bed positioned between the storage and in-use positions; and

FIG. 20 is a front isometric view of the wall bed of FIG. 18, showing the bed in the in-use position.

The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the preferred embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is susceptible of embodiment in many different forms. While the drawings illustrate, and the specification describes, certain preferred embodiments of the invention, it is to be understood that such disclosure is by way of example only. There is no intent to limit the principles of the present invention to the particular disclosed embodiments.

Turning initially to FIGS. 1-4, an encased foldable bed 10 is movable between a retracted storage position (FIGS. 1 and 2) and a deployed in-use position (see FIG. 4) to provide a safe and sanitary sleeping space that maximizes available space surrounding the bed 10.

The illustrated bed 10 is preferably configured for use in facilities that provide provisional boarding, such as hospitals, college dormitories, apartments, nursing homes, military barracks, etc. However, the principles of the present invention are applicable where the bed 10 is used in more permanent housing situations or anywhere where beds may be used.

It has been found that the bed 10 is especially well suited for use in hospital rooms and other healthcare facilities accommodating overnight or prolonged stays to patients, visitors, and caregivers. For instance, the encased structure of the bed 10 provides an easily maintained sanitary condition. Furthermore, the bed 10 can be quickly moved into the storage position to provide ample space for hospital personnel and equipment, which is often critical in emergency situations.

The bed 10 is configured to have a maximum load capacity of five hundred pounds (500 lb), which generally complies with hospital obesity requirements. Preferably, the bed 10 provides a safety factor of two (2), which corresponds to the bed 10 being able to support a static load of one thousand pounds (1000 lb) without part failure of permanent deformation. It should be noted, however, that the present invention is not limited to use in hospitals; therefore, the present invention is not limited to a specific load capacity. Beds having a higher or a lower load capacity may be used without departing from the spirit of the present invention.

The bed 10 broadly includes a housing frame 12, a bed frame 14, a pivot assist assembly 16, an auto-synchronized leg deployment assembly 18, and a casing 20.

The housing frame 12 facilitates connection of the bed 10 to the structure (e.g., building, room, wall, etc.) and provides support to other parts of the bed 10, as will be discussed. In the illustrated embodiment, the frame 12 may be secured to a surface S of a structure (see FIG. 12). However, the present invention is equally applicable to wall beds that are built into, or recessed in, a structure. For instance, the bed made be built into a wall of a structure without departing from the spirit of the present invention.

The housing frame 12 of the illustrated embodiment has an overall rectangular shape. However, certain aspects of the present invention are equally applicable to housing frames of any size and/or shape.

Turning to FIG. 6, the housing frame 12 includes a pair of spaced apart, vertically coextensive frame sections 22. A horizontally-extending frame member 24 is connected between the vertical frame sections 22. The frame 12 further includes a plurality of brace members 26 extending horizontally between the frame sections 22. It is noted that certain aspects of the present invention apply to housing frames formed from a single unitary piece of material.

Preferably, the vertical frame sections 22 comprise sixteen (16) gauge steel that is stamped into the illustrated shape. The sections 22 preferably include a powder coated finish (not shown). It will be readily understood by those having ordinary skill in the art, however, that certain aspects of the present invention are equally applicable to wall bed configurations wherein the vertical housing frame sections comprise an alternative material and/or are alternatively formed.

The vertical frame sections 22 of the illustrated embodiment include a left frame member 28 and a right frame member 30. Because the frame members 28 and 30 are virtually mirror images of one another and for the sake of brevity, the description will focus on the members 28 and 30 collectively, with the components being similarly numbered.

Preferably, the vertical frame sections 22 have an overall rectangular shape and present opposed inner and outer surfaces 32 and 34. The surfaces 32 and 34 extend between spaced apart ends, including a top end 36, a bottom end 38, a front end 40, and a back end 42.

The frame sections 22 include a plurality of through holes 44 extending transversely through the surfaces 32 and 34. As will be described in greater detail below, each through hole 44 is arranged to align with corresponding holes in the casing 20 to facilitate secure arrangement of the casing 20 with fasteners 46.

The illustrated frame sections 22 preferably include inwardly projecting flanges or tabs at corresponding ends. More particularly, the sections 22 include a bottom end flange 48, a front end flange 50, and a back end flange 52. As will be discussed in greater detail below, the flanges (48, 50, and 52) facilitate secure arrangement of the casing 20 and cross members 26, and provide additional stability to the bed 10.

Preferably, a support plate 54 arranged on the lower margin of the inner surface 32 extending between the end flanges 40 and 42 (see FIGS. 6 and 8). Preferably, the support plate 54 is secured to the inner surface 32 by fastenerless means such as welding. As will be described in greater detail below, a pivot rod bracket 56 is arranged on the plate 54 in alignment with a pivot rod hole 58 passing transversely through the plate 54 and the surfaces 32 and 34.

The horizontally-extending frame section 24 has an overall rectangular shape. Preferably, the frame section 24 is comprised of sixteen (16) gauge steel that is stamped into the illustrated shape. The section 24 preferably includes a powder coated finish (not shown). It will be readily understood by those having ordinary skill in the art, however, that certain aspects of the present invention are equally applicable to wall bed configurations wherein the housing frame sections comprise an alternative material and/or are alternatively formed.

The illustrated frame member 24 includes upper and lower surfaces 60 and 62 extending between spaced apart ends. The ends preferably include a front end 64, a back end 66, and a pair of space apart side ends 68.

The illustrated frame member 24 also preferably includes downwardly projecting flanges or tabs at corresponding ends. More particularly, the member 24 preferably includes, a back end flange 70, and a pair of spaced apart side end flanges 72. In the operable arrangement, the frame member 24 engages the top ends 36 of the vertical frame sections 22 with the inner surface 62 is abutment with the top ends 36 of the vertical frame sections 22. With frame members 22 and 24 operably arranged, the side flanges 72 overhang the outer surfaces 34 of the frame sections 22, and the back flange 70 overhangs with the back end flanges 52 (see FIGS. 6 and 8).

Preferably, the frame section 24 is secured to the vertical frame sections 22 by fastenerless means such as welding. However, the frame sections 22 and 24 may be mechanically fastened without departing from the spirit of the present invention.

The illustrated frame member 24 includes a plurality of through holes 74 extending transversely through the surfaces 60 and 62. As will be described in greater detail below, each through hole 74 is arranged to align with corresponding holes in the casing 20 to facilitate secure arrangement of the casing 20 with fasteners 46.

As perhaps best shown in FIG. 8, a pair of stop assemblies 78 are arranged on the lower surface 62 of the horizontally-extending frame section 24. The stop assemblies 78 include a stop fixed to an angled mounting plate that is securely positioned on the lower surface 62 (. When the bed 10 is moved into the storage position, the stop assemblies 78 ensure that the corresponding margins of the housing frame 12 and the bed frame 14 are substantially aligned. More particularly, the stop assemblies 78 engage the casing 20 covering the bed frame 14 to prevent the bed frame 14 from retracting too deep into the storage space 80. Preferably, the casing 20 on the front ends 40 and 64 will align flushly with the casing 20 on the bottom of the bed frame 14 when the bed 10 is in the storage position, which reduces the accumulation of contaminates within the storage space 80.

As perhaps best shown in FIGS. 6 and 9, the illustrated brace members 26 extend horizontally between the frame sections 22 providing additional stability to the housing 12. Preferably, the brace members are spaced equidistant along the back ends of frames sections 22. It is noted, however, the housing may be alternatively braced without departing from the spirit of the present invention. Furthermore, certain aspects of the present invention apply equally to housing frame configurations without bracing. In the illustrated embodiment, four (4) spaced apart brace members 26 are secured to the back ends 42 of the frame sections 22. The illustrated brace members 26 include a pair of substantially flat rectangular bars 82 and a pair of angled braces 84.

The bars 82 and braces 84 preferably comprise eleven (11) gauge steel that is stamped into the illustrated shape. The bars 82 and braces 84 preferably include a powder coated finish (not shown).

The bars 82 are preferably arranged on intermediate portions of the frame sections 22 between the angled braces 84, which are arranged near the ends 36 and 38. The angled braces 84 include a vertical margin 86 angled at approximately ninety degrees (90°) from an inwardly extending margin 88 (see FIG. 6). The angled braces 84 are arranged to engage the back end flanges 52 with the inward margin 88 disposed in abutment with the inner surface 32 of the frame sections 22.

As will be discussed in greater detail below, a pair of mounting cleats 90 are fixed to the housing to facilitate surface mounting of the bed 10 (see FIG. 12). Preferably, the mounting cleats are secured to the housing frame 12 at the braces 84 with welding and/or mechanical fasteners. It is noted that the present invention is not limited to the use of the mounting cleats 90 of the illustrated embodiment. The bed 10 may be alternatively secured to the surface of a structure without departing from the spirit of the present invention. Furthermore, as previously discussed, the present invention is not limited to surface mounted applications.

The bed frame 14 of the illustrated embodiment has an overall rectangular shape presenting proximal and distal portions 92 and 94. However, as with the housing frame, the present invention is not limited to any particular size or shape.

The illustrated frame 14 includes a pair of spaced apart, coextensive side members 96, which define a majority of the rectangular length of the frame 14, and a plurality of horizontal members 98 arranged between the side members 96. The frame members 96 and 98 are preferably comprised of tube steel. The members 96 and 98 have a substantially rectangular shape presenting top and bottom faces and a pair of spaced apart side faces. As will be described in greater detail below, the horizontal members 98 are preferably joined to the side members 96 by welding. It should be understood that the bed frame of the present invention may be alternatively constructed without departing from the spirit of the present invention. For instance, bed frames formed from alternative frame members, or comprised of a single unitary piece are within the ambit of the present invention.

Each side member 96 has a rod hole (not shown) passing transversely through the side faces at the proximal and distal ends 94 and 92. With the side members 96 operably arranged, the rod holes of respective members 96 are in general alignment with each other so that corresponding pivot rods may pass therethrough.

The horizontal members 98 include proximal and distal end members 104 and 106, and intermediate members 108 arranged between the end members 104 and 106 (see FIG. 6). As will be discussed, the proximal end member 104 extends horizontally past the side members 96 at the proximal portion 94 to facilitate attachment of the assisted pivot assembly 16 (see FIG. 11). Preferably, the distal end member 106 extends between the side members 96 at the distal portion 92 with the front face of the end member 106 being in flush alignment with the ends of the side members 96 (see FIG. 6).

As mentioned above, the horizontal members 98 are preferably welded to the side members 96. To increase the surface area of the weld, and thereby increase the strength of the weld, triangular gussets 110 are arranged at the interface of the members 96 and 98 (see FIG. 6).

As will be described in greater detail below, the bed frame 14 is at least partially supported on the housing frame 12 by a proximal end pivot rod 112. The pivot rod 112 extends through the rod holes at the proximal end 92 of the bed frame 14 and the pivot rod holes 58 of the support plates 54. As perhaps best shown in FIG. 16, a bushing or sleeve 101 is arranged in the rod holes of the side members 96 to facilitate smooth movement of the bed 10 between the storage and in-use positions.

The pivot rod 112 is fastened to the vertical frame sections 22 at respective pivot rod brackets 56. As perhaps best shown in FIG. 10, the pivot rod 112 includes through holes 114 arranged in vertical alignment with corresponding holes 115 in the brackets 56 when the bed 10 is operably arranged. With the holes 114 and 115 aligned, fastener 116 (depicted in the illustrated embodiment as a threaded bolt and nut) extends therethrough to facilitate secure arrangement of the pivot rod 112. Preferably, with this arrangement of the rod 112 and brackets 56, the pivot rod 112 is disposed in corresponding pivot rod holes 58 of the vertical frame sections 22 such that the ends 118 of the pivot rod 112 are in flush alignment with the outer surface 34 of corresponding frame sections 22 (see FIG. 6).

The bed frame 14 is also supported on the housing frame 12 by the pivot assist assembly 16. The pivot assist assembly 16 preferably includes a pair of pistons 120 operably connected to the housing frame 12 and the bed frame 14. However, other types of pivot assist assemblies are within the ambit of the present invention. For example, certain aspects of the present invention are equally applicable to pivot assist assemblies comprised of springs and/or other counter balancing means.

Each piston 120 of the illustrated embodiment is a gas filled piston and generally includes a gas compression chamber and an extendable piston arm; however, other types of pistons may be used without departing from the spirit of the present invention. Preferably, the pistons 120 have a gas spring force ranging from five hundred Newtons (500 N) (N=Newton=1 kg·m/s²) to nine hundred Newtons (900 N). More preferably, the pistons 120 have a gas spring force ranging from about seven hundred Newtons (700 N) to about eight hundred Newtons (800 N). It is noted that certain aspects of the present invention apply equally to the use of pistons that provide more or less spring force.

The lower end of each piston 120 is pivotally secured to the bed frame 14 at a respective bracket 122 secured to the proximal end member 104. Each bracket 122 is preferably welded to a respective end of the proximal end member 104 (see FIG. 10). Each bracket 122 preferably presents a main body with a curved gusset portion extending therefrom. The main body is configured to abut a respective end of the proximal end member 104. The curved gusset portion is configured to engage the front face of the proximal end member 104. The main body of each bracket 122 includes a plurality of through holes and a laterally projecting stud 124. Each piston 120 is secured to a respective bracket 122 by engagement of stud 124 and a corresponding stud socket defined in lower end of the piston 120.

The upper end of each piston 120 is pivotally secured to the housing frame 12 by an upper respective bracket 126 secured to a corresponding vertical frame member 22. Each bracket 126 preferably includes a mounting flange with a body portion projecting therefrom. Each bracket 126 is preferably secured to a respective vertical frame member 22 by fasteners passing transversely through corresponding holes in the mounting flange of the bracket and end flange 52 of the respective vertical frame section 22 (see FIG. 6). The body portion of the bracket 126 is fitted with a laterally projecting stud (not shown). Each piston 120 is secured to a respective bracket 126 by the mating engagement of stud and a corresponding stud socket defined in upper end of the piston 120.

With the bed 10 operably arranged in the storage position, the pistons 120 are fully extended. Forces exerted by the pistons 120 are sufficient to hold the bed frame 14 in the storage position. However, the bed 10 may be locked in this position by any suitable latches or locking mechanisms.

The auto-synchronized leg deployment assembly 18 of the present invention automatically deploys one or more support legs as the bed is moved into the in-use position, and automatically retracts the leg (or legs) as the bed is moved into the storage position.

The leg deployment assembly 18 of the illustrated embodiment preferably includes a distal end pivot rod 128, a proximal end pulley 130, a distal end pulley 132, and a drive element 134.

With the bed 10 operably arranged, the pivot rod 128 extends through the rod holes at the distal end 92 of the bed frame 14 with the ends of the pivot rod 128 projecting beyond the outer face of the respective side members 96. As perhaps best shown in FIG. 16, a bushing or sleeve 101 is arranged in the rod holes at the distal portion 92 of the side members 96 to facilitate smooth rotation of pivot rod 128 as the bed is moved between the in-use and storage positions.

A leg 136 is fixed to each of the respective ends of the distal end pivot rod 128. Preferably, the material comprising the legs 136 is aluminum. However, the legs may be formed from other materials without departing from the spirit of the present invention. For instance, certain aspects of the present invention apply equally to legs formed from other metals or polymers. As will be apparent, for certain applications of the present invention, the legs may be encased with the casing material.

As perhaps best shown in FIGS. 16 and 17, each pulley 130 and 132 has an overall cylindrical shape. The illustrated pulleys 130 and 132 include a body portion 140 and a drive engaging portion 142. However, certain aspects of the present invention are not limited to the illustrated pulley construction. For instance, alternative leg deployment assemblies wherein the pulleys include only a drive engaging portion are within the ambit of the present invention.

Each pulley 130 and 132 of the illustrated embodiment preferably includes a centrally located rod opening extending axially therethrough through to facilitate arrangement of the pulleys 130 and 132 on pivot rods 112 and 128, respectively.

Each pulley 130 and 132 also includes a slot or channel 146 extending radially outward from, and axially along the rod opening. A threaded hole 148 extends radially through the outer surface of the body 140 to the slot 146. As will be discussed, the slots 146 and the threaded holes 148 facilitate secure arrangement of the pulleys 130 and 132 on the pivot rods 112 and 128, respectively.

The illustrated drive engaging portion 142 of each pulley 130 and 132 has a circular in shape. The drive engaging portion 142 includes a pair of spaced apart, circumferentially extending walls 150 that project radially to define a circumferential drive channel 152 therebetween. The drive element 134 engages each pulley 130 and 132 at the drive channel 152 when the bed 10 is operably arranged. Preferably, the diameters of respective drive channels 152 will be different to provide a preloaded drive element 134 (see FIG. 17). A preloaded drive element 134 reduces unwanted leg movement when the bed 10 is in the in-use position.

As will be discussed, each pulley 130 and 132 preferably includes a drive socket 154 to facilitate attachment of the drive element 134. The illustrated drive socket 154 is defined by aligned notches formed in the drive engaging portion 142 of each pulley 130 and 132. Preferably, as will be explained, a ninety degree (90°) angle is defined between the threaded hole 148 and the drive socket 154 of the proximal end pulley 130 and a one hundred thirty five degree (135°) angle is defined between the threaded hole 148 and the drive socket 154 of the distal end pulley 132 (see FIG. 17).

The illustrated pulley 132 includes a wedge-shaped stop margin 156 projecting axially from the body 140. As will be discussed, the stop margin 156 restricts the rotation of the pulley 132 within a desired range.

The illustrated drive element 134 is a steel cable. More particularly, the illustrated drive element 134 includes two (2) sections of steel cable interconnected by a pair of cable couplers 158 (see FIGS. 6 and 10). The tension of the drive element 134 can be adjusted at the couplers 158. It should be understood that certain aspects of the present invention are equally applicable to alternatively constructed drive elements. For instance, linked drive elements (such as chains) may be used without departing from the spirit of the present invention. Additionally, a drive element formed a single continuous length of material is within the ambit of the present invention.

The illustrated drive element 134 preferably includes a pair of spherical cable balls 160. With the bed 10 operably arranged, each cable ball 160 is received in the drive socket 154 of a respective pulley (130, 132). Preferably, the diameter of the cable ball 160 will be greater than the width dimension, and less than the height dimension, of the drive channel 152 to facilitate secure arrangement of the drive element 134.

As perhaps best shown in FIG. 16, the pulleys 130 and 132 are preferably arranged on respective pivot rods 112 and 128 with the pulley slots 146 positioned in alignment with corresponding slots 162 of the pivot rods (112 and 128). With the slots 146 and 162 aligned, a rectangular key 164 is positioned therebetween. As perhaps best shown in FIGS. 16 and 17, with the key 164 arranged in the slots 146 and 162, a threaded stud 166 is arranged in the threaded hole 148 to secure the key 164 within the aligned slots 146 and 162. Securing the pulleys 130 and 132 to respective pivot rods as described and shown enables lateral adjustment of the pulleys 130 and 132 when the bed 10 is assembled or thereafter. However, other means of securing the pulleys to the pivot rods may be used without departing from the spirit of the present invention.

Preferably, proximal and distal end rod brackets 168 and 170 are arranged on the bed frame 14 to provide additional support to the pivot rods 112 and 128. More particularly, the proximal end rod bracket 168 is preferably arranged on an intermediate member 98, and the distal end bracket 170 is preferably arranged on the distal member 106 (see FIGS. 6 and 16). The pivot rods 112 and 128 pass through holes formed in the respective brackets 168 and 170. A bearing or sleeve 172 is preferably arranged in the holes of the brackets 168 and 170 to facilitate smooth movement of the bed 10 between the storage and in-use positions. As will be discussed, the distal end rod bracket 170 preferably includes a stop flange 174 fitted with a stop 176 that engages the stop margin 156 of the distal end pulley 132.

With the bed 10 operably arranged in the in-use position, an angle of approximately ninety degrees (90°) is defined between the housing frame 12 and the bed frame 14 (with the housing frame 12 defining a substantially vertical axis and bed frame 14 defining a substantially horizontal or perpendicular axis, see FIGS. 4-6). With the bed 10 in this arrangement, each pulley 130 and 132 is fixed to a respective pivot rod (112, 128) such that the corresponding drive sockets 154 face in opposite directions and are substantially centered on the plane perpendicular to the vertical axis defined by the housing frame 12 (see FIGS. 7, 11, and 17).

Turning to FIGS. 13-15, as the bed 10 is moved between the storage and in-use positions, the bed frame 14 rotates or pivots about the stationary proximal end rod 112. Because the tension in the drive element 152 remains constant, the distal end pulley 132 is forced to rotate proportionately with the bed frame 14, which consequently causes the rod 128 to rotate. The rotation of the distal end pivot rod 128 causes the legs 136 to retract as the bed 10 is moved to the storage position from the in-use position.

Similarly, as the bed 10 is moved from the storage position to the in-use position, the rotation of the distal end pivot rod 128 causes the legs 136 to deploy. As discussed above, when the legs 136 are fully deployed (approximately 90° relative to the bed frame 14) the stop margin 156 of the distal end pulley 132 engages the stop 176 of the distal end rod bracket 170.

Preferably, the legs 136 are perpendicular to the bed frame 14 when the bed 10 is in the in-use position (see FIGS. 4-7, and 16), and parallel to the bed frame 14 when the bed 10 is in the storage position (see FIG. 13).

Turning now to the illustrated casing 20. Preferably the casing 20 substantially encloses or surrounds the surfaces of the bed housing 12 and the bed frame 14 to define an outermost circumambient surface 178 of the bed (see FIGS. 1-5). The casing 20 facilitates a sanitary bedding environment by reducing the spaces wherein dust and other contaminants can accumulate, and by providing a substantially continuous outer surface that is easy to clean.

The casing 20 also provides a physical barrier between users and the mechanical components of the bed 10. More particularly, as will be discussed in greater detail below, the pivot assist assembly 16 and the leg deployment assembly 18 are arranged beneath the casing 20 to prevent unintentional user contact therewith. Furthermore, the casing 20 preferably presents rounded corners and edges, which reduces the likelihood of injuries associated with bumping into, or otherwise contacting, the bed 10.

The illustrated casing 20 is formed from a plurality of panel sections 180 arranged to define the outermost circumambient surface 178. As will be discussed in greater detail below, the panel sections 180 are configured to fit together in complementary relation on corresponding portions of the bed housing 12 and the bed frame 14. As used herein to describe the panel sections 180, “complementary,” “complementary relation,” “complementary dimension,” and similar variations of the foregoing terms refer to the snug, engaging and/or abutting arrangement of the panels 180 relative to one another and/or other portions of the bed 10.

The illustrated panels 180 generally have an overall rectangular shape. However, it should be noted that alternative panel designs may be used without departing from the spirit of the present invention.

The illustrated panels 180 are preferably formed from a blow-molded composite resin. It will be readily appreciated by one of ordinary skill in the art, however, that the casing 20 could be alternatively configured without departing from the spirit of the present invention. Furthermore, certain aspects of the present invention apply equally to fastenerless casing configurations.

The blow molding method used to form the panels 180 generally consists of combining the resin, a coloring agent, and an antimicrobial agent (“resin mixture”) in a mixing drum or other suitable mixing container. In the drum, the resin mixture heated and a rotating screw agitates the mixture. Once sufficiently mixed, the resin mixture is drawn into an accumulator head. The resin/additive mixture is then extruded through a die orifice in a cylinder shape (parison) where air is introduced to keep the parison from collapsing. The mold is closed around the parison and cooled to take the shape of the panel 180 corresponding to the mold. This molding process may be facilitated by Western Industries, Incorporated—Plastic Products Group located in Winfield, Kans. It is noted, however, that the panels 180 may be formed from other methods without departing from the spirit of the present invention.

With regard to the resin material, it has been found that fractional melt high density polyethylene resins are suitable for purposes of the present invention. One such suitable resin material is Marlex® HHM 5502BN, which is manufactured by Chevron Phillips Chemical Company LP. Another suitable resin material is Petrothene® LR734011, which is manufactured by LyondellBasell Industries Holdings. It is noted that the present invention is not limited to foregoing resin materials and that other suitable resins may be used without departing from the spirit of the present invention.

As mentioned above, a coloring agent and an antimicrobial agent are preferably combined with the resin during the formation of the illustrated panels 180. The coloring agent and the antimicrobial agent are preferably combined with the composite resin using gravimetric blending equipment. A suitable coloring agent can be purchased from National Plastics Color, Incorporated, located at 100 west Industrial, Valley Center, Kans. 67147. However, the present invention is not limited to the use any particular coloring agent. Other coloring agents are within the ambit of the present invention. Furthermore, certain aspects of the present invention apply equally to casing formulations devoid of coloring additives.

The antimicrobial agent is combined with the resin to prevent the growth of bacteria, mold, and yeast on the panels 180. A suitable antimicrobial agent is Irgaguard® B 5000, which is manufactured by BASF Corporation. Additional information pertaining to Irgaguard® B 5000 can be found by contacting the manufacturer. It is noted that the present invention is not limited to any particular antimicrobial agent, and certain aspects of the present invention apply equally to casing formulations devoid of antimicrobial agents.

The panels 180 preferably include a textured surface. More particularly, after the panels 180 are formed, the outer surface of panels 180 is preferably etched using liquid acid to provide an etched texture that effectively hides scrapes and blemishes while maintaining a substantially smooth surface to clean and disinfect easily.

Turning now to the arrangement of the illustrated casing 20, the panel sections 180 corresponding to the bed housing 12 include a top panel 182, outer side panels 184, a back panel 186, inner side panels 188, and a bottom panel 190.

Preferably, the top panel 182 has a rectangular shape and presents opposed top and bottom surfaces 192 and 194 extending between spaced apart ends. More particularly, the surfaces 192 and 194 extend between a back end 196, a front end 198, and a pair of side ends 200.

The top surface 192 defines the uppermost margin of the circumambient surface 178 (see FIGS. 1 and 4). When arranged on the housing frame 12, the ends 198 and 200 preferably overhang corresponding side panels 184 (see FIGS. 2 and 9). This arrangement of the panels 182 and 184 facilitates substantial continuity of the circumambient surface 178 about the interface of the frame sections 22 and 24.

The bottom surface 194 is arranged to abut the top surface 60 of frame member 24, and includes a plurality of fastener receiving holes 202 formed therein. The fastener receiving holes 202 are arranged to align with corresponding through holes 74 in the frame member 24 to facilitate secure arrangement of the casing 20 with fasteners 46.

The outer side panels 184 of the illustrated embodiment include a left side panel 206 and a right side panel 208. Because the panels 206 and 208 are virtually mirror images of one another and for the sake of brevity, the description will focus on the panels 206 and 208 collectively, with the components being similarly numbered.

Preferably, the panels 184 have a rectangular shape and present opposed inner and outer surfaces 208 and 210 extending between spaced apart ends. More particularly, the surfaces 208 and 210 extend between a top end 212, a bottom end 214, a front end 216, and a back end 218.

The inner surface 208 is arranged to abut the outer surface 34 of the respective frame section 22, with the top end 212 in abutment with the bottom surface 194 of the top panel 182. The arrangement of the panels 182 and 184 facilitates substantial continuity of the circumambient surface 178 about the storage space 80 and at the interface of the panels 182 and 184.

The front end 216 preferably defines an inwardly projecting shoulder 220 extending between the top end 212 and the bottom end 214. The shoulder 220 presents opposed fore and aft surfaces 222 and 224 and an end margin 226. As will be described in greater detail below, the inner side panels 188 are arranged to abut the shoulder 220, which provides substantial continuity to the circumambient surface 178 about the vertical frame sections 22 and at the interface of the panels 184 and 188.

The inner surface 208 includes a plurality of fastener receiving holes 202. The fastener receiving holes 202 are arranged to align with through holes and corresponding through holes in inner side panels 188, as will be described.

On the lower margin, the shoulder 220 includes through holes 228 passing transversely therethrough. The through holes 226 are arranged to align with through holes in the bottom panel 190 to facilitate secure arrangement of the casing 20 with fasteners 46.

The back panel 186 has a rectangular shape and presents opposed front and back surfaces 230 and 232 extending between spaced apart ends. More particularly, the surfaces 230 and 232 extend between a top end 234, a bottom end 236, and a pair of side ends 238.

As perhaps best shown in FIG. 9, and 12-15, the back panel 186 fits snugly within the interior of the housing frame 12 with the ends 234 and 238 arranged in abutment with margin 88 and the inner surfaces 32, respectively. The top and side perimetrical margins along the back surface 232 are arranged to abut the inner surface of the flanges 32, facilitating substantial continuity of the circumambient surface 178 about the storage space 80.

Preferably, the side ends 239 include fastener slots 240 arranged to align with corresponding holes 242 in the back end flange 52 of the frame sections 22 (see FIG. 9). Preferably, casing fasteners 244 are used to secure the back panel 186 to the frame sections 22. However, the back panel 186 may be alternatively secured without departing from the spirit of the present invention.

With the bed 10 operably arranged, the back surface 186 preferably engages the bars 82 of the housing frame 12. As will be described in greater detail below the, the inner side panels 188 are arranged to abut the front surface 230 to facilitate substantial continuity of the circumambient surface 178 within the storage space 80 (see FIGS. 4, 5 and 7).

At the lower margin of the panel 186, a recessed margin 246 is defined in the ends 238 (see FIGS. 7 and 9). As will be described in greater detail below, the recesses 246 partly define respective piston storage spaces 248.

The inner side panels 188 of the illustrated embodiment include upper and lower inner panels 250 and 252.

The upper inner panels 250 of the illustrated embodiment include a left upper panel 254 and a right upper panel 256. Because the upper inner panels 254 and 256 are virtually mirror images of one another and for the sake of brevity, the description will focus on the panels 254 and 256 collectively, with the components being similarly numbered.

The illustrated panels 250 have an overall rectangular shape and present opposed inner and outer surfaces 258 and 260 extending between spaced apart ends. More particularly, the surfaces 258 and 260 extend between a top end 262, a bottom end 264, a front end 266, and a back end 268. It is noted, however, that the panels 180 may be alternatively configured without departing from the spirit of the present invention.

The illustrated panels 250 include a plurality of through holes 270 passing transversely through the surfaces 258 and 260. The holes 270 are arranged to align with corresponding through holes 44 and receiving holes 202 to facilitate secure arrangement of the casing 20 with fasteners 46. Again, it should be understood that alternative securely arranging the panels 180 may be used without departing from the spirit of the present invention.

Although the casing 20 of the illustrated embodiment comprises panels 180 that are secured to the bed 10 using mechanical fasteners, certain aspects of the present invention apply to fastenerless casing configurations. For example, panels having interlocking components to facilitate snap-together assembly are within the ambit of the present invention. Furthermore, certain aspects of the present invention applies to overmolded casing configurations. However, one benefit of a bed having mechanically fastened or snap-fit casing configurations is the ability to remove or replace the casing (or portions thereof) as need be.

In the illustrated embodiment, plugs 272 are used to cover the opening of holes 270. The plugs 272 are preferably formed from the same material as the panel sections 180. The arrangement of the plugs 272 facilitates substantial continuity of the circumambient surface 178 on the panels 180. It is noted that alternative plugs or covering means are within the ambit of the present invention.

With the bed operably arranged, the inner surfaces 258 engage the inner surfaces 32 of corresponding frame sections 22, with the top end 262 in abutment with the lower surface 62 of the upper frame section 24. More particularly, the inner surfaces 258 include a central margin 274 that projects between the flanges 50 and 52 to be in substantially flush engagement with the inner surface 32 of a respective frame sections 22 (see FIG. 8).

The front ends 266 of panels 250 are arranged to abut the shoulder 220 of respective outer side panels 184. More particularly, the front end 266 is arranged to abut the aft surface 224 of the shoulder 220, with the outer surface 260 and the end margin 226 being substantially coterminous. Additionally, the back ends 268 of the panels 250 are arranged to abut the front surface 230 of the back panel 186. This arrangement of the panels 180 facilitates substantial continuity of the circumambient surface 178 about the storage space 80 and at the interface of panel 250 with panels 184 and 186.

The lower inner panels 252 of the illustrated embodiment include a left lower panel 276 and a right lower panel 278. Because the lower panels 276 and 278 are virtually mirror images of one another and for the sake of brevity, the description will focus on the panels 276 and 278 collectively, with the components being similarly numbered.

The illustrated panels 252 present an upper margin 280 and a lower margin 282. As will be discussed, the upper margin 280 has an overall rectangular shape, and the lower margin 282 is irregularly shaped (see FIG. 8).

The panels 252 present opposed inner and outer surfaces 284 and 286 extending between spaced apart ends. More particularly, the surfaces 284 and 286 extend between a top end 288, a bottom end 290, a front end 292, and a back end 294.

Preferably, the panels 252 include a plurality of through holes 270 passing transversely through the surfaces 284 and 286. The holes 270 are arranged to align with corresponding through holes 44 and receiving holes 202 to facilitate secure arrangement of the casing 20 with fasteners 46.

Preferably, plugs 272 are used to cover the opening of holes 270, facilitating substantial continuity of the circumambient surface 178 on respective panels 180. Again, alternative plugs or covering means are within the ambit of the present invention.

With the bed operably arranged, the panels 250 and 252 are arranged to abut at the ends 264 and 288, respectfully. Preferably in this arrangement, the outer surfaces 260 and 286 are substantially coextensive to define corresponding sides of the storage space 80. This arrangement of the panels 180 provides substantial continuity to the circumambient surface 178 about the storage space 80 and at the interface of panels 250 and 252.

In a similar manner as the upper panels 250, the lower panels 252 are arranged to abut the shoulder 220 at the front end 292, facilitating substantial continuity of the circumambient surface 178 about the storage space 80 and at the interface of panels 184 and 188.

The inner surfaces 284 include a central portion 296 that projects to flushly engage the inner surface 32 of a respective frame sections 22. As with the upper panels 250, the central portion 296 of the upper margin 280 fits snugly between the flanges 50 and 52. At the lower margin 282, the width of the central portion 296 is reduced to facilitate fore and aft movement of the pistons 120 associated with movement of the bed 10 between the storage and in-use positions (see FIGS. 8 and 9). In this arrangement, the piston space 248 is defined between the panels 252 and respective frame sections 22 (see FIGS. 7 and 9).

Preferably, the central portions 296 terminate in abutment with the top portion of the support plate 54 on respective frame sections 22, with bottom end 290 arranged above the pivot rod bracket 122.

As will be described in greater detail below, a guide or track 300 is preferably defined on the back end 294 of the lower margin 282 to facilitate movement of a headboard.

The illustrated bottom panel 190 has an overall rectangular shape presenting front and back surfaces 302 and 304 extending between spaced apart ends. More particularly, the surfaces 302 and 304 extend between a top end 306, a bottom end 308, and a pair of side ends 310. Again it is noted, that the panels 180 may be alternatively configured without departing from the spirit of the present invention.

Preferably, the back surface 304 is arranged to abut the shoulder 220 at the aft surface 224, facilitating substantial continuity of the circumambient surface 178 about the housing 12 and at the interface of panels 184 and 190. A plurality of through holes 270 pass transversely through the surfaces 302 and 304. The illustrated panel 190 is arranged with the holes 270 in alignment with the corresponding holes 228 of the shoulder 220.

Preferably, casing fasteners 46 are arranged through the holes (228 and 270) to facilitate secure arrangement of the panel 190. It should be understood that alternative means of securely arranging the panels 180 may be used without departing from the spirit of the present invention. Furthermore, certain aspects of the present invention apply to fastenerless casing configurations. Preferably, plugs 272 cover the opening of holes 270 to facilitate substantial continuity of the circumambient surface 178 about the bed 10. Again, alternative plugs or covering means are within the ambit of the present invention.

As will be described in greater detail below, the bottom panel 190 and the casing 20 corresponding to the bed frame 14 are arranged to substantially enclose the lower portion of the storage space 80 when the bed 10 is in the storage and in use positions. The arrangement of the panel 190 and the casing 20 on the bed frame 14 facilitates substantial continuity of the circumambient surface 178 about the bed 10 and at the interface of panel 190 and the casing 20 on the bed frame 14.

Turning to FIGS. 10 and 11, the panel sections 180 corresponding to the bed frame 14 include a top side panel 312 and a bottom side panel 314. Preferably, as will be discussed, panel sections 312 and 314 present complementary dimensions, which fit together in mating relation to substantially enclose the bed frame 14.

The top side panel 312 has a rectangular shape presenting opposed top and bottom surfaces 316 and 318 extending between spaced apart ends. More particularly, the surfaces 316 and 318 extend between a front end 320, a back end 322, and a pair of side ends 324. Again, it is noted that the panels 180 may be alternatively configured without departing from the spirit of the present invention.

The top surface 316 defines a recessed bed pan 326. The shape and dimensions of the bed pan 326 facilitates arrangement of a mattress 328 at least in partly within the bed pan 326. Preferably, strips of hook-and-loop fasteners (not shown) are arranged on the bed pan 326 and the mattress 326 to secure arrangement of the mattress 328. However, the mattress 328 may be alternatively secured without departing from the spirit of the present invention.

Turning briefly to the mattress, the mattress 328 of the present invention is preferably constructed to be in compliance with health and safety regulations pertaining to mattresses. However, certain aspects of the present invention apply equally to the use of non-compliant mattresses.

The illustrated mattress 328 is shown schematically in the drawing figures. Although not depicted in the drawing figures, the mattress 328 preferably includes a mattress core, a perimeter support, a flame barrier, and a cover. It is noted that the present invention is not limited to any particular mattress design and other mattresses may be used without departing from the spirit of the present invention.

The mattress core is preferably formed from a plurality of layers including a bottom or substrate layer, a middle layer, and a top layer. However, the mattress core may be formed from more or less layers without departing from the spirit of the present invention. For instance, mattress cores formed from a single layer or more than three (3) layers are within the ambit of the present invention. The layers of the mattress core preferably comprise medical grade memory foam, but other mattress core materials may be used without departing from the spirit of the present invention.

The perimeter support provides additional support to the outer perimeter margin of the mattress 328. In general it has been found that providing additional support to the outer perimeter margin increases the longevity of the mattress, maintains the overall shape of the mattress, and makes it easier for users to enter and exit the bed. Preferably, the perimeter support is a box-like structure formed from a pair of side members and a pair of end members. However, other perimeter support structures are within the ambit of the present invention.

The flame barrier surrounds the mattress core and the perimeter support to reduce the flammability of the bed. Preferably, the flame barrier is formed from a material that complies with California Technical Bulletin 129. More information pertaining to California Technical Bulletin 129 can be found by contacting the California Department of Consumer Affairs. It has been found that Integrity30®, a fire barrier manufactured by Ventex, Inc., is a suitable fire barrier product.

The cover prevents contamination of the mattress 328 and includes a moisture resistant zipper and welded seams. The mattress cover is preferably made from a material that provides flame resistance, fluid resistance, antibacterial and antifungal properties. Additionally, it is important that the material used for the mattress cover be able to withstand frequent exposure to various chemical cleaning agents. It has been found that Dartex® P467, a fabric material manufactured by Dartex Coatings Incorporated, is suitable for many applications of the present invention. The cover preferably includes a moisture resistant zipper arranged lengthwise on the bottom part of the cover. It has been found that AquaGuard®, a zipper manufactured by the YKK Corporation, is a suitable moisture resistant zipper.

The mattress 328 is preferably assembled by first securing the substrate and middle mattress core layers to each other. Preferably, the layers are secured to each other using an adhesive material. The perimeter support is then secured to the outer perimeter of the substrate and middle mattress core layers using an adhesive material. The top mattress core layer is arranged over the top of the middle mattress core layer and the perimeter support, and secured thereto using an adhesive material. It is noted that the mattress core and perimeter support may be assembled using alternative securing means without departing from the spirit of the present invention. The assembled mattress core and perimeter support is enclosed with the fire barrier and placed in the cover.

Preferably, the mattress 328 has a rectangular length of seventy-six inches (76″) and a rectangular width of thirty-six inches (36″). The thickness of the mattress 328 preferably ranges between five inches (5″) and ten inches (10″). It is noted that the mattresses having different shapes and dimensions may be used with departing from the spirit of the present invention.

Returning to the description of the panels 180, the panel 312 includes a transition margin 330 extending from the outer perimeter of the bed pan 326 at the ends 320 and 324. Preferably, the transition margin 330 is gradually curved (as opposed to sharply angled) between the between the outer perimeter of the bed pan 326 and the ends 320 and 324, which facilitates secure arrangement of the mattress 328 and simple cleaning of the upper bed panel 312.

The top side panel 312 includes a plurality of through holes 270 passing transversely through the surfaces 316 and 318. As will be discussed, the holes 270 are arranged to align with the corresponding holes 202 in the lower panel 314 (see FIG. 10).

The bottom surface 318 preferably includes a plurality of lengthwise channels 332 and a plurality of widthwise channels 334. Preferably, the channels 332 and 334 present depth and width dimensions that are complementary to the dimensions presented by the members 96 and 98 of the bed frame 14. In this way, the bed frame 14 is disposed, at least in part, within the channels 332 and 334 when the bed 10 is operably arranged. As will be discussed in greater detail below, the channels 332 and 334 are arranged to be in alignment with channels of the lower bed panel 314 to substantially enclose the bed frame 14 and facilitate substantial continuity of the circumambient surface 178 about the bed frame 14.

The ends (320-324) of the top side panel 312 preferably present a face portion 336 that defines the outermost lateral perimeter of the upper bed panel 312. As perhaps best shown in FIG. 11, the face portions 336 extend from the top surface 316 to an end margin 338 that projects beyond the adjacent portion of the bottom surface 318. With this arrangement of the panels 312 and 314, the ends (320-324) partly define a perimetrical channel. As will be described in greater detail below, the end margins 338 of the top side panel 312 are arranged in abutment with the bottom side panel 314 so that the perimeter of the bed frame 14 is substantially enclosed by the casing 20. This arrangement of the panels 180 facilitates substantial continuity of the circumambient surface 178 about the bed frame 14 and at the interface of the panels 312 and 314.

The face portions 336 at the side ends 324 preferably include notched portions to facilitate interconnection and operable movement of the various components of the bed. More particularly, a leg notch 340 is defined in the face 336 of the side ends 324. The leg notch 340 has dimensions complementary to the shape of the leg 136 so that a respective portion of the leg 136 fits snugly therein.

The illustrated panel 312 includes a rod opening or notch 342 is defined the faces 336 at the end 324. The rod notch 342 presents a dimension complementary to the shape of the proximal pivot rod 112 such that the proximal pivot rod 112 fits snugly within substantially all of the area defined by the rod notch 342 when the bed 10 is operably arranged. The snug arrangement of the pivot rod 112 within rod notch 342 provides substantial continuity to the circumambient surface 178 about the bed frame 14 and at the interface of panels 312 and 314 with rod 112.

The bottom side panel 314 of the illustrated embodiment has a rectangular shape presenting opposed top and bottom surfaces 344 and 346 extending between spaced apart ends, including a front end 348, a back end 350, and a pair of side ends 352. Again it is noted, that the panels 180 may be alternatively configured to have different shapes and dimensions without departing from the spirit of the present invention.

Preferably, the top surface 344 of the bottom side panel 314 and the bottom surface 318 of the top side panel 312 are complimentary such that when the panels 312 and 314 substantially enclose (or encase) the bed frame 14 and portions of the leg deployment assembly 18 when the bed 10 is operably arranged. The complementary arrangement of the panels 312 and 314 facilitates substantial continuity to the circumambient surface 178 about the bed frame 14, which enables a sanitary bedding environment. The complementary arrangement of the panels 312 and 314 and reduces the risk of injury that could be caused by movement of the bed 10 between the storage and in-use positions.

The top surface 344 of panel 314 includes a plurality of lengthwise and widthwise channels 354 and 356. Preferably, the channels 354 and 356 present depth and width dimensions that are complementary to the dimensions presented by the members 96 and 98 of the bed frame 14 to facilitate snug engagement between the panel 312 and the bed frame 14. In this way, the bed frame 14 is disposed, at least in part, within the channels 332 and 334 when the bed 10 is operably arranged.

As previously discussed, the illustrated channels (332, 334, 354, and 356) of respective panels 312 and 314 are arranged in alignment with each other so that the bed frame 14 is substantially enclosed (or encased). The alignment of the channels (332, 334, 354, and 356) provides sufficient space to accommodate movement of the leg deployment assembly 18 between the operably arranged panels 312 and 314 (see FIG. 13). More particularly, with the bed 10 in the operable arrangement, the aligned channels 332 and 354 provide sufficient space for movement of the pulleys (130 and 132) and the drive element 134 as the bed 10 is pivoted between the storage and in-use positions.

The illustrated panel 314 includes a plurality of fastener receiving holes 202 extending transversely through the top surface 344. Preferably, the holes 202 of the top surface 344 are arranged to align with the corresponding holes 270 in the top side panel 312 to facilitate secure arrangement of the casing 20 with fasteners 46 (see FIG. 10).

The bottom side panel 314 preferably includes a handle or pull 358 formed in the bottom surface 346 to facilitate movement of the bed 10 between storage and in-use positions.

The ends (348-352) of the bottom side panel 314 each include a face portion 362 that forms the outermost lateral perimeter of the panel 314. As perhaps best shown in FIGS. 7 and 10, the face portions 362 extend perpendicularly upward (when the bed is in an in-use position) from the bottom surface 346 to an end margin 364 that projects beyond the adjacent portion of the top surface 344. In this arrangement, the ends (320-324) partly define the perimetrical channel. In the operable arrangement, the end margins 338 and 364 come together to enclose the outer perimeter of the bed frame 14. This arrangement of the margins 338 and 364 provides substantial continuity to the circumambient surface 178 about the bed frame 14 and at the interface of the panels 312 and 314.

Similar to the top side panel 312, a leg notch 366 is formed into the face 362 of side end 352. In the operable arrangement, the leg notches 342 and 366 align and cooperatively present a dimension complementary to the shape of the leg 136, such that when the bed 10 is arranged in the storage position, the leg 136 fits within the space defined the notches 342 and 366. The leg notch 366 extends toward the bottom surface 346 to an opening 360 to facilitate deployment and retraction of the legs 136.

A rod notch 368 is also formed in the face 362 of each side end 352. In the operable arrangement, the rod notches 342 and 368 are in general alignment to cooperatively present a shape that complements the shape of the pivot rod 112, such that the pivot rod 112 fits within and occupies substantially all of the area defined by the notches 342 and 368. The arrangement the notches 342 and 362 provides substantial continuity to the circumambient surface 178 about the bed frame 14 and at the interface of the panels 312 and 314.

As mentioned above, the bed 10 preferably includes a foldable headboard assembly. The headboard assembly 370 of the illustrated embodiment broadly includes a frame 372 and hingedly connected to headboard panels 374.

As perhaps best shown in FIG. 10, the illustrated headboard frame 372 includes a horizontal mounting flange 376 connected to respective side members 96 of the bed frame 14 by a pair of rectangular vertical frame members 378.

The frame members 378 preferably comprise tube steel similar to that of the bed frame 14. Preferably, the bottom portion of each frame member 378 is welded to the top margin of a respective side member 96.

The mounting flange 376 is preferably angled at ninety-degrees (90°) to present two (2) portions. The mounting flange 376 is preferably arranged on the vertical members 378 with one portion overlying the top margin of the vertical members 378 and the other portion overhanging to engage the front margin of the vertical members 378. In this arrangement, the flange 376 is welded to the vertical members 378.

The headboard panels 374 include a head panel 380 and a base panel 382. The base panel 382 is vertically arranged over the side members 96 and includes a pair of spaced apart frame notches 384 in the bottom margin to facilitate mating engagement with respective side members 96. The base panel 382 is secured to the mounting flange 376 by a plurality of fasteners 386 passing transversely through the flange 376 and into the back side of the panel 382.

With the bed 10 operably arranged, the panels 312 and 314 engage the base panel 382 at ends 322 and 350, respectively (see FIGS. 5 and 7). This arrangement of the panels facilitates substantial continuity of the circumambient surface 178 about the storage space 80 and at the interface of the between the panels 180 and the headboard assembly 370.

The base panel 382 also includes spaced apart knuckles 388 at the top margin. The head panel 380 includes spaced apart knuckles 390 at the bottom margin. The knuckles 388 of the base panel 382 are arranged to be offset relative to the knuckles 390 of the head panel 380 to facilitate interlocking engagement of the panels 380 and 382. More particularly, when the panels 380 and 382 are brought together, the knuckles 388 of the base panel 390 fit within the spaces defined between the knuckles of the head panel 380, and the knuckles 390 of the head panel 380 fit within the spaces defined by the knuckles 388 of the base panel 382. Each of the knuckles 388 and 390 has a bore or through hole configured to receive a hinge rod 392. With the panels 380 and 382 arranged with respective knuckles horizontally aligned, the hinge rod 392 extends through the bores to hingedly connect the panels 380 and 382 (see FIG. 11). This arrangement of the panels 380 and 382 provides substantial continuity to the circumambient surface 178 about the storage space 80 and at the interface of panels 380 and 382.

The head panel 380 preferably includes a pair of spring plungers 394 located at a respective top corner of the head panel 380 (see FIG. 10). As mentioned above, the spring plungers 394 include a stud that projects laterally outward into the track or guide 300 defined in the back end 294 of respective inner side panels 252. When the bed 10 is pivoted between the storage and in-use positions, the stud of the spring plunger 394 travels along the track 300 as the head panel 380 hinges about the axis defined by the hinge rod 392.

Preferably, with the bed 10 operably arranged, the side margins of the panels 380 and 382 abut (or are spaced slightly away from) the inner surface 284 of respective inner side panels 252 to effectively enclose the mechanical space defined at the lower margin of the housing 12 (when the bed is in the in-use position). This arrangement of the panels 380, 382, and 252 facilitates substantial continuity of the circumambient surface 178 about the bed 10 and at the interface of panel 252 and the headboard assembly 370.

A second preferred bed 510 is illustrated in FIGS. 18-20. It is initially noted that, with certain exceptions to be discussed in detail below, many of the elements of the bed 510 of the second embodiment are the same as or very similar to those described in detail above in relation to the bed 10 of the first embodiment. Therefore, for the sake of brevity and clarity, redundant descriptions and numbering will be generally avoided here. Unless otherwise specified, the detailed descriptions of the elements presented above with respect to the first embodiment should therefore be understood to apply at least generally to the second embodiment, as well.

Although not shown in the drawing figures, the bed 510 includes a housing frame and a bed frame. Because the bed 510 presents a horizontal rectangular length (rather than the vertical rectangular length presented by bed 10), the length of corresponding frame members/sections will differ from those presented by the bed 10. Otherwise, the elements of housing and bed frames 12 and 14 generally apply to bed 510.

The bed 510 has a substantially rectangular shape. As with the bed 10 of the first embodiment, however, foldable beds having different shapes and dimensions are generally within the ambit of the present invention.

The bed 510 broadly includes a housing frame (not shown), a bed frame (not shown), a pivot assist assembly (not shown), a leg deployment assembly 512, and a casing 514.

The concepts and features pertaining to the housing frame 12, bed frame 14, and pivot assist assembly 16 of the bed 10 generally apply to the bed 510. As will be understood by those having ordinary skill in the art, however, the dimensions of the housing frame, bed frame, and pivot assist assembly of bed 510 will, in some instances, present different overall dimensions given the orientation of the rectangular length of the bed 510 as compared to the bed 10.

The general principles pertaining to the leg deployment assembly 18 of the first embodiment will generally apply to the leg deployment assembly 512 of the second embodiment. Preferably, the leg deployment assembly 512 includes three (3) support legs 516 spaced equidistant on the bed 510. More particularly, the assembly 512 includes a centrally located leg 518 arranged between a pair of spaced apart side legs 520. It is noted, however, that certain aspects of the present invention apply equally to beds having additional or fewer legs than depicted in the illustrated embodiment.

As with bed 10 of the first embodiment, the casing 514 substantially encloses or surrounds the surfaces of the bed housing 12 and the bed frame to define an outermost circumambient surface 522 of the bed 510.

The casing 514 arranged on the housing frame generally includes a top panel 524, outer side panels 526, a back panel 528, inner side panels 530, and a bottom panel 532.

The casing 514 arranged on the bed frame generally includes an upper panel 534 and a lower panel 536. Similar to the bed 10 of the first embodiment, the panels 534 and 536 include notched face portions, as shown, to facilitate leg deployment/retraction and bed rotation. As shown, the lower panel 536 preferably includes a central leg notch 538 to facilitate deployment and retraction of the center leg 518.

The bed 510 also preferably includes a headboard assembly 540. The headboard assembly includes an upper panel 542 and a lower panel 544.

Although the above description presents features of preferred embodiments of the present invention, other preferred embodiments may also be created in keeping with the principles of the invention. Furthermore, these other preferred embodiments may in some instances be realized through a combination of features compatible for use together despite having been presented independently in the above description

The preferred forms of the invention described above are to be used as illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.

The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims. 

What is claimed is:
 1. A foldable wall bed comprising: a housing frame configured to be secured to a structure, said housing frame defining a storage space; a bed frame configured to support a mattress, said bed frame presenting a proximal end pivotally secured to the housing frame, said bed frame being pivotable about an axis between a storage position and an in-use position; and a casing substantially enclosing the housing frame and the bed frame to define an outermost circumambient surface of the bed when the bed is arranged in the storage position and the in-use position.
 2. The foldable wall bed as claimed in claim 1, said housing frame including a box-like structure formed from a pair of vertical frame sections and an uppermost horizontal frame section.
 3. The foldable wall bed as claimed in claim 2, said housing frame including horizontal brace members extending between the vertical frame sections.
 4. The foldable wall bed as claimed in claim 1, said bed further including a lift-assist assembly arranged beneath the circumambient surface and being configured to reduce the amount of force necessary to move the bed from the in-use position to the storage position.
 5. The foldable wall bed as claimed in claim 4, said lift-assist assembly including a pair of gas pistons.
 6. The foldable wall bed as claimed in claim 5, each of said pistons include upper and lower ends operably arranged on the housing frame and the bed frame, respectively.
 7. The foldable wall bed as claimed in claim 1, said bed further including an auto-synchronized leg deployment assembly configured to deploy a support leg when the bed is moved to the in-use position and retract the leg when the bed is moved to the storage position.
 8. The foldable wall bed as claimed in claim 7, said auto-synchronized leg deployment assembly being arranged beneath the circumambient surface.
 9. The foldable wall bed as claimed in claim 1, said casing including a plurality of interlocking panels.
 10. The foldable wall bed as claimed in claim 8, said panels being formed by blow molding.
 11. The foldable wall bed as claimed in claim 1, said casing comprising a high density polyethylene resin.
 12. The foldable wall bed as claimed in claim 1, said casing including an antimicrobial agent.
 13. A foldable wall be comprising: a housing frame configured to be secured to a structure, said housing frame defining a storage space; a bed frame configured to support a mattress, said bed frame presenting a proximal end pivotally secured to the housing frame, said bed frame being pivotable about an axis between a storage position and an in-use position; and an auto-synchronized leg deployment assembly, said leg deployment assembly being configured to deploy a support leg when the bed is moved to the in-use position and retract the leg when the bed is moved to the storage position.
 14. The foldable wall bed as claimed in claim 13, said housing frame having a rectilinear shape formed from a pair of vertical frame sections and an uppermost adjacent frame section.
 15. The foldable wall bed as claimed in claim 14, said housing frame including horizontal brace members extending between the vertical frame sections.
 16. The foldable wall bed as claimed in claim 13, said bed further including a lift-assist assembly configured to reduce the amount of force necessary to move the bed from the in-use position to the storage position.
 17. The foldable wall bed as claimed in claim 13, said bed further including a casing substantially enclosing the housing frame and the bed frame, said casing defining an outermost circumambient surface of the bed when the bed is arranged in the storage position and the in-use position.
 18. The foldable wall bed as claimed in claim 17, said auto-synchronized leg deployment assembly being arranged beneath the circumambient surface.
 19. The foldable wall bed as claimed in claim 18, said casing including a plurality of interlocking panels.
 20. The foldable wall bed as claimed in claim 19, said panels being formed by blow molding.
 21. The foldable wall bed as claimed in claim 18, said casing comprising a high density polyethylene resin.
 22. The foldable wall bed as claimed in claim 18, said casing including an antimicrobial agent.
 23. The foldable wall bed as claimed in claim 18, said leg deployment assembly being arranged beneath the casing. 